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dirtbikersa

1996 Honda CR125 Fork Info

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Posted (edited)

Gday all, 

I am currently rebuilding a 1996 Honda CR125 and busy with the front suspension. By accident I loosened the shim stack in the damper rod and wasn't really paying attention to the correct order for the shims. 

Could try and remove the shims carefully from the other side damper rod and try figure out the order but I am concerned I don't get it out easily and loose the correct order. 

Was wondering if anyone perhaps knows the factory shim stack layout/order for the KYB 43mm front forks. 

Also looking for any setup advice or improvements that can be made while its apart. 

Thank you! 

Edited by dirtbikersa

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I'm tidying up the shelves these days, are you looking for this stack?

mid.PNG

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with original peening just removed, same stack as the one posted by Mog

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23 hours ago, hondino said:

I'm tidying up the shelves these days, are you looking for this stack?

mid.PNG

Yes that is the one I am referring to. Is a special too required to disassemble it from the tube? Thats where I went wrong, I removed the top nut thinking that I would now slide out of the tube and all the shims came out! DOH!! Been looking everywhere for more information on disassembly but haven't found much. 

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The tube requires a lot of heat to break the thread lock ,and protect the rod 

 

I put the fork cap back on to hold it against 

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Posted (edited)

to extract it from the tube, i unscrew the rod locknuts

''''''''''''.PNG

Edited by hondino
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inside there is a split circlip with its seat,

the following photo is the original stack

11111..PNG

stack 43.PNG

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Posted (edited)

Thanks guys, bloody legends!! My shims dont look the best anymore! Some are warped?! Will see if I can source new ones somewhere. 

And the circlip was broken😏

Edited by dirtbikersa

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The circlip us meant to be in 2 halves 

  • Haha 1

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Posted (edited)

Gents, are you able to confirm if there is supposed to be a spring with the plunger? When I disassembled the forks there was no spring. Parts no longer available.

also what is the correct orientation of the plunger, on the honda parts finder it appears to be facing upwards, while it appears to be facing down in service manual. 

 

image.png.98ef75e14a5a3930f54f394b5c9ab270.pngThis is from Honda Parts Finder

image.png.1c57fe48349075b3e3c07685b2e2bc02.png Service Manual

 

 

 

Edited by dirtbikersa

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